Composite Foam Article

ABSTRACT

A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article also comprises at least one supplemental layer comprising an ethylene and acrylic acid copolymer dispersed in and/or disposed between any of said aforementioned skins and core.

FIELD OF THE DISCLOSURE

The subject disclosure generally relates to a composite foam article.The composite foam article can be used in automotive applications.

DESCRIPTION OF THE RELATED ART

In the transportation industry, there is a focus on making vehicularinteriors comfortable, quiet, and aesthetically pleasing for drivers andpassengers alike. In the automotive industry, interior components suchas headliners, headliner substrates, visors, package trays, seats, andload floors serve structural, acoustic, and aesthetic purposes toprovide drivers and passengers with a comfortable, quiet, andaesthetically pleasing driving experience.

There is a need for headliners and other components with improvedperformance.

SUMMARY OF THE DISCLOSURE AND ADVANTAGES

The subject disclosure provides a composite foam article. The compositefoam article comprises a polyurethane foam core presenting a firstsurface and a second surface facing opposite the first surface. A firstskin is disposed on the first surface and a second skin is disposed onthe second surface. The first and second skins comprise a plurality offibers and a polymeric binder.

In some embodiments, the polyurethane foam core has a density of fromabout 45 to about 80, kg/m³. In these embodiments, the polyurethane foamcore, the first skin, and the second skin have a pre-compressionthickness of from about 2 to about 5 mm, and are compressed to form thecomposite foam article having a strength of greater than about 17 N at apost-compression thickness of greater than about 2 mm when tested inaccordance with SAE J949 at about 23° C.

In further embodiments, the composite foam article comprises at leastone supplemental layer comprising an ethylene and acrylic acid (EAA)copolymer dispersed in and/or disposed between any of saidaforementioned skins and core.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages of the present disclosure will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings. It is to be understood that the drawings are purelyillustrative and are not necessarily drawn to scale.

FIG. 1 is a perspective view of a vehicle interior including a seat anda headliner including the composite foam article of the subjectdisclosure.

FIG. 2 is an expanded cross-sectional view of an embodiment of thecomposite foam article of this disclosure which can be used as anautomotive headliner substrate.

FIG. 3 is a graph illustrating the strength of the composite foamarticle tested in accordance with SAE J949 at a thickness of about 4 mm.

FIG. 4 is a graph illustrating the stiffness of the composite foamarticle tested in accordance with SAE J949 at a thickness of about 4 mm.

FIG. 5 is a graph illustrating the strength of the composite foamarticle tested in accordance with SAE J949 at a thickness of about 2 mm.

FIG. 6 is a graph illustrating the stiffness of the composite foamarticle tested in accordance with SAE J949 at a thickness of about 2 mm.

FIG. 7 is a graph illustrating the strength of the composite foamarticle and various comparative foam articles tested in accordance withSAE J949 at a thickness of about 4 mm.

FIG. 8 is a graph illustrating the stiffness of the composite foamarticle and various comparative foam articles tested in accordance withSAE J949 at a thickness of about 4 mm.

FIG. 9 is a graph illustrating the strength of the composite foamarticle and various comparative foam articles tested in accordance withSAE J949 at a thickness of about 2 mm.

FIG. 10 is a graph illustrating the stiffness of the composite foamarticle and various comparative foam articles tested in accordance withSAE J949 at a thickness of about 2 mm.

FIG. 11 is another expanded cross-sectional view of an embodiment of thecomposite foam article of this disclosure which can be used as anautomotive headliner substrate.

FIG. 12 is an exploded cross-sectional view of an embodiment of thecomposite foam article of this disclosure which can be used as anautomotive headliner coverstock.

FIG. 13 is an exploded perspective view of the composite foam articlesof Examples 3-6.

FIG. 14 is a graphical analysis of the sound absorption of Example 6 andComparative Example 8.

FIG. 15 is a graphical analysis comparing the peel strength between thefirst skin (on the “A side” of the substrate) and the polyurethane foamcore of Examples 3, 4, and 5 and Comparative Examples 5, 6, and 7.

FIG. 16 is a graphical analysis comparing the peel strength between thesecond skin (on the “C side” of the substrate) and the polyurethane foamcore of Examples 3, 4, and 5 and Comparative Examples 5, 6, and 7.

FIG. 17 is a graphical analysis of the strength of Examples 3-6 andComparative Examples 5-8.

FIG. 18 is a graphical analysis of the stiffness of Examples 3-6 andComparative Examples 5-8.

FIG. 19 is a graphical analysis of the sag of Examples 3 and 4 andComparative Examples 5 and 6.

FIG. 20 is an enlarged image of the additional layer comprising the EAAcopolymer and polyurethane foam core of Example 4.

DETAILED DESCRIPTION OF THE DISCLOSURE

A composite foam article is disclosed herein and generally shown at 10throughout the Figures. The composite foam article 10 comprises apolyurethane foam core 12 presenting a first surface 14 and a secondsurface 16 facing opposite the first surface 14. A first skin 18 isdisposed on the first surface 14, and a second skin 20 is disposed onthe second surface 16. The composite foam article 10 is particularlysuitable for use in interior automotive components such as seats,headliner substrates, headliners, visors, package trays, and loadfloors. Referring now to FIG. 1, the composite foam article 10 can beused in an interior automotive component within a vehicle interior 2,e.g. in a headliner 6 or in a seat 4 of an automobile.

However, the composite foam article 10 of the subject disclosure is notlimited to use in the automotive industry. As one example, the compositefoam article 10 is suitable for use in the aerospace industry, e.g. inairplanes. As another example, the composite foam article 10 is suitablefor use in the furniture industry, e.g. in beds, couches, and chairs.

As set forth above, the composite foam article 10 includes thepolyurethane foam core 12. The polyurethane foam core 12 presents afirst surface 14 and a second surface 16 facing opposite the firstsurface 14.

The polyurethane foam core 12 includes the reaction product of anisocyanate and an isocyanate-reactive component, e.g. an activehydrogen-containing compound such as a polyol, in the presence of ablowing agent. The polyurethane foam core 12 can be an isocyanate-basedpolymer selected from the group of polyurethane, urea-modifiedpolyurethane, and carbodiimide-modified polyurethane. The term“modified”, when used in conjunction with a polyurethane means that upto 50% of the polymer linkages have been substituted. In someembodiments, the polyurethane foam core 12 is a semi-rigid polyurethanefoam. In various preferred embodiments, the polyurethane foam core 12 isa semi-rigid polyurethane foam.

In various embodiments, the polyurethane foam core 12 is a foam typeselected from at least one of viscoelastic foam, flexible foam,semi-rigid foam, and rigid foam. For example, in some embodiments, e.g.where the composite foam article 10 is a seat cushion, a seat cover, ora headliner coverstock, the polyurethane foam core 12 may compriseflexible or viscoelastic foam. In other embodiments, e.g. where thecomposite article 10 is a sun visor, seat back, package tray, load or aheadliner substrate, the polyurethane foam core 12 may comprisesemi-rigid or rigid foam. Further, the polyurethane foam core 12 caninclude one or more sublayers of foam. The sublayers may comprisevarious combinations of the foam types set forth above.

The polyurethane foam core 12 is typically formed via an exothermicreaction of an isocyanate-reactive resin composition (including polyols)and an isocyanate in the presence of a blowing agent. Theisocyanate-reactive resin composition, the isocyanate, and the blowingagent, are collectively known as a polyurethane system. Suitablepolyurethane foams and polyurethane systems are commercially availablefrom The Woodbridge Group of Woodbridge, ON.

In some embodiments, including headliner embodiments, slabstockpolyurethane foam is produced for the polyurethane foam core 12 inmanufacturing facilities in the form of foam “buns” having dimensionssuch as 4 feet (height)×6 feet (width)×100 feet (length). Each bun isthen cut into a plurality of shorter length (e.g. 8 feet) buns,depending on the specifications of the particular automotive headlinerbeing produced. The shorter length bun is then sliced into sheets ofappropriate thickness (e.g. 2 to 12 mm).

In some embodiments, including headliner embodiments, the polyurethanefoam core 12 has an initial thickness of from about 2 to about 15, fromabout 2 to about 12, from about 2 to about 10, from about 2 to about 5,from about 3 to about 6, or from about 3 to about 10,mm. In variousnon-limiting embodiments, all values and ranges of values including andbetween those described above are hereby expressly contemplated for useherein.

In many embodiments, the polyurethane foam core 12 has an initial(before compression if included in a compressed interior component)density of from about 24 to about 180, from about 40 to about 120, fromabout 22 to about 80, from about 45 to about 80, from about 50 to about80, or from about 55 to about 75, kg/m³. In various non-limitingembodiments, all values and ranges of values including and between thosedescribed above are hereby expressly contemplated for use herein.

Although density is not a measure of firmness, stiffness, or loadbearing capacity, such properties can be characterized by CompressionForce Deflection (“CFD”). In some embodiments, where the polyurethanefoam core 12 is a semi-rigid foam, e.g. semi-rigid polyurethane foam foruse in headliners and load floors, the polyurethane foam core 12 has aCFD at 10% deflection of from about 10 to about 120, or from about 15 toabout 100, or from about 30 to about 95, or from about 40 to about 90,or from about 50 to about 90, or from about 60 to about 90, or fromabout 70 to about 90, PSI when tested in accordance with ASTMD3574-17-D. In various non-limiting embodiments, all values and rangesof values including and between those described above are herebyexpressly contemplated for use herein.

It should be appreciated each of the layers described herein can be inincluded in the composite foam article 10 more than once. It should alsobe appreciated that each of the different types of layers describedherein can include one or more sub layers comprising the materialsdescribed herein with respect to that particular layer. Further, thelayers described herein can be included in different locations withinthe composite foam article 10. Of course, the layers can be formed withvarious combinations of film, powder, particles, and fibers. As will beapparent when reading the subject disclosure and referencing thecorresponding figures (e.g. FIGS. 2, 11, 12, and 13), various exemplary,non-limiting embodiments that illustrate the use of different numbers oflayers in different locations within the composite foam article 10 aredescribed and contemplated herein.

As will be apparent when reading the subject disclosure and referencingthe corresponding figures (e.g. FIGS. 2-5) a prime after a numeralgenerally denotes a second of a particular type of layer. For example,the composite foam article 10 typically includes one or more additionalor supplemental polymeric layers 24. As such, a polymeric layer 24 couldbe located on one side of the foam core layer 12 and a second and thirdpolymeric bonding layer 24′, 24″ could be located on the other side ofthe polyurethane foam core 12 as is illustrated in FIG. 2.

Referring now to FIG. 2, in some embodiments, the composite foam article10 includes the first skin 18 disposed on the first surface 14, and thesecond skin 20 disposed on the second surface 16. In most embodiments,the first and/or the second skin 18, 20 is in the form of a porousmaterial layer such as a layer of chopped fiberglass, a veil, a mat, orthe like. Although a porous layer is not specifically illustrated in thedrawings, e.g. in FIG. 2, it should be appreciated that the first and/orthe second skins 18, 20 are represented as a single layer although theycomprise multiple components arranged in a porous configuration. Thatis, in the drawings, the first and second skins 18, 20 include aplurality of fibers and a polymeric binder, which are represented by twosub layers one of which is meant to represent the plurality of fibers,and the other meant to represent the polymeric binder. It should beappreciated that the plurality of fibers and the polymeric bindercombine to form each skin 18, 20. The first and second skins 18, 20 caninclude like or different components (e.g. fibers, binder, etc.) and canbe included in the composite foam article 10 in like or differentamounts (e.g. different weight per unit area, or different thicknesses).

It should be appreciated that FIGS. 2, 11, 12, and 13 are not drawn toscale and are for illustrative purposes. To this point, an additional orsupplemental polymeric layers 24 would typically be thinner than a firstor second skin 18, 20, but this difference is not depicted in theFigures as such.

The plurality of fibers may be alternatively described as the fibers orthe fiber. The plurality of fibers may be woven, non-woven, or any othersuitable construction. The plurality of fibers can be naturallyoccurring or synthetic. The plurality of fibers may include variouscombinations of the types of fibers set forth.

In various embodiments, the plurality of fibers are, include, comprise,consist essentially of, or consist of, a material selected frompolymers, ceramic, glass, metal, mineral, and carbon. In variousembodiments, the fibers are, include, comprise, consist essentially of,or consist of: aramid fibers, carbon fibers, cellulose fibers (includingkenaf and hemp), acrylic fibers, polyvinyl alcohol fibers, glass fibers,mineral fibers, metal fibers, and combinations thereof.

In some embodiments, the plurality of fibers comprise a polymer. Thatis, the plurality of fibers comprise, consist essentially of, or consistof, a polymer.

For example, in some such embodiments, the plurality of fibers includearamid or aromatic polyamide. In many embodiments, the fibers, include,comprise, consist essentially of, or consist of, aromatic polyamide,i.e., aramid. Aramid fibers are a class of heat-resistant and strongsynthetic fibers. In some embodiments, the aromatic polyamide is ameta-aramid fiber. In other embodiments, the aromatic polyamide is apara-aramid. The aramid fibers may be pulp or flock of various lengthsand diameters.

Aramids are typically formed by reacting amines and carboxylic acidhalides. In one embodiment, the aramid is further defined as having atleast about 85 percent of amide linkages (—CO—NH—) attached directly totwo aromatic rings. In some embodiments, additives can be used with thearamid, and it has been found that up to as much as 10 percent, byweight, of other polymeric material can be blended with the aramid orthat copolymers can be used having as much as 10 percent of otherdiamine substituted for the diamine of the aramid or as much as 10percent of other diacid chloride substituted for the diacid chloride ofthe aramid. To this end, the aramid fibers contemplated and disclosedherein also include aramid copolymers, e.g. polymers including amide andother linkages. In some embodiments, the aromatic polyamide is selectedfrom the group of poly-paraphenylene terephthalamide,poly-meta-phenylene isophthalamide, polyether-polyurea copolymer(elastane), and mixtures thereof.

In some embodiments, the plurality of fibers comprise polyester. Forexample, a terephthalic acid based polyester. Non-limiting examples ofterephthalic acid based polyester include poly(ethylene terephthalate)(PET), polybutylene terephthalate (PBT), Polytrimethylene terephthalate(PTT), and Polyethylene naphthalate (PEN). In other embodiments, theplurality fibers comprise a poly(aromatic ester) selected from the groupof poly-paraphenylene terephthalamide, poly-meta-phenyleneisophthalamide, polyether-polyurea copolymer (elastane), and mixturesthereof.

In other embodiments, the plurality of fibers comprise mineral or glass.That is, the plurality of fibers comprise, consist essentially of, orconsist of a glass. In such embodiments, the plurality of fibers cancomprise a glass type selected from at least one of E-glass(alumina-calcium-borosilicate), S2 glass (magnesium-alumino-silicate), Cglass (calcium borosilicate), and R glass. In some embodiments, theplurality of fibers can comprise a mineral type selected from at leastone of silica, basalt, and quartz.

All weight ranges and ratios of the various combinations of theaforementioned fiber types are hereby expressly contemplated in variousnon-limiting embodiments.

In a typical embodiment including the first and second skins 18, 20,each of the skins 18, 20 comprise a single, porous layer. Alternatively,each of the skins 18, 20 can comprise a plurality of porous layers. Insuch embodiments, it is possible to use from 2 to 15 porous layers, from2 to 12 porous layers, from 2 to 10 porous layers, from 2 to 8 porouslayers, or from 4 to 8 porous layers.

The first and the second skins 18, 20 also comprise a polymeric binder.In various embodiments, the binder is, includes, comprises, consistsessentially of, or consists of, a polymer. The polymeric binder mayinclude various combinations of the types of polymers set forth. Somenon-limiting examples of polymers include epoxies, polyurethanes,polyureas, phenolics, polyacrylates, silicones, polysulfides,polyolefins, polyesters, nylons, polyvinylchlorides, latex,styrene-butadiene polymers, nitrile-butadiene polymers, mixturesthereof, copolymers thereof and interpenetrating networks thereof. Insome embodiments, the polymeric binder comprises a polymer selected frompolyethylene and polypropylene.

As alluded to above, the composite foam article 10 may include one ormore additional or supplemental polymeric layers 24 different than thepolymeric binder. If included, the additional or supplemental polymericlayers 24 can be included in the composite as or formed from a powder,scrim, or film. Such layers can be disposed on the first and/or secondsurface 14, 16 of the polyurethane foam core 12 to improve adhesion ofthe skin 18, 20 to the polyurethane foam core 12. Alternatively, in someembodiments, the additional or supplemental layers 24 can beincorporated into the skin 18, 20 and/or disposed on the skin 18, 20.

Of course, the one or more additional polymeric layers 24 comprise apolymer. In some embodiments, the polymer is a thermoplastic. In otherembodiments, the polymer is a thermoplastic elastomer. In otherembodiments, the polymer is an elastomer. In some embodiments, thepolymer is a thermoset comprising epoxy, polyurethane, polyurea,phenolic, acrylate, arylate, silicone, polysulfide, polyester, andmixtures thereof. Various non-limiting examples of polymers which can beused include polyolefins, polyesters, nylons, poly(vinyl chloride),polyurethanes, polyacrylates, latex, styrene-butadiene polymers,nitrile-butadiene polymers, silicone polymers, polyisobutylene, mixturesthereof, copolymers thereof and interpenetrating networks thereof.

In some preferred embodiments, the one or more additional polymericlayers 24 comprise a polyolefin.

In some preferred embodiments, the one or more additional polymericlayers 24 comprise polyethylene, polyethylene terephthalate, ethyleneand acrylic acid copolymer (“EAA copolymer”), polyethylene,polypropylene, and combinations thereof.

In some such embodiments, the at least one additional layer 24 (e.g.comprising EAA copolymer) is utilized in an amount from about 8 to about30, from about 10 to about 20, or from about 10 to about 15 (e.g. 13),g/m². In various non-limiting embodiments, all values and ranges ofvalues including and between those described above are hereby expresslycontemplated for use herein.

Further, in some embodiments, the at least one additional layer 24 (e.g.comprising EAA copolymer) is utilized as a film having a tensileelongation of from about 200 to about 400% MD and from about 350 toabout 550% TD when tested in accordance with ASTM D882. In variousnon-limiting embodiments, all values and ranges of values including andbetween those described above are hereby expressly contemplated for useherein.

In some embodiments, the additional polymeric layer(s) 24 comprises EAAcopolymer and is formed from film or powder disposed on the first and/orsecond surface 14, 16 of the polyurethane foam core 12 to improveadhesion of the skins 18, 20 to the polyurethane foam core 12.Alternatively the additional or supplemental layers 24 can beincorporated into the skin 18, 20 and/or disposed on the skin 18, 20.When EAA copolymer is utilized, it offers excellent adhesion to thepolyurethane foam core 12. FIGS. 11 and 12, which are described indetail below, are an exploded view of the various layers of thecomposite foam article 110, 210 which utilizes supplemental layer(s)124, 124′, 224 comprising EAA copolymer.

In some embodiments, the additional or supplemental layers 24 comprisingEAA copolymer are formed from a single layered EAA copolymer film. Inother embodiments, the additional or supplemental layers 24 comprisingEAA copolymer are formed from a multi-layered EAA copolymer film. Thesupplemental layers 24 of such film embodiments can be the same ordifferent. In some examples, the film utilizes multiple layers of EAAcopolymer film. In other examples, the film comprises one or more layersincluding a first polymer (e.g. EAA copolymer) and one or more layerscomprising a second polymer (e.g. polyethylene).

For example, in some embodiments, the additional or supplementallayer(s) 24 comprises EAA copolymer, and is formed from multiplesub-layers comprising different polymer types. In some particularexamples, the supplemental layer 24 includes a first sub-layercomprising EAA copolymer, a second sub-layer comprising polyethylene orpolypropylene, and a third sub-layer comprising polyethylene orpolypropylene (e.g. in a configuration wherein the second sub-layer isdisposed between the first and the third sub-layers. In many preferredembodiments, the first sub-layer comprising EAA copolymer is coronatreated.

That is, a surface of the additional or supplemental layer(s) 24 can becorona treated. When the additional or supplemental layer(s) 24 is usedto promote adhesion of the various layers of the composite foam article10, to the surface of the polyurethane foam core 12. The corona treatedsurface is of the additional or supplemental layer(s) 24 abuts the firstor the second surface 14, 16 of the polyurethane foam core 12. Forexample, in some embodiments, where the supplemental layer 24 isutilized to improve the adhesion of the various layers of the compositefoam article 10 to the polyurethane foam core 12, the supplemental layer24 includes a corona treated first sub-layer comprising EAA copolymer, asecond sub-layer comprising polyethylene or polypropylene, and a thirdsub-layer comprising polyethylene or polypropylene and the compositefoam article is formed (e.g. laminated) with the corona treated firstsub-layer comprising EAA copolymer facing the polyurethane foam core 12.In one particular embodiment, the supplemental layer 24 includes acorona treated first sub-layer comprising EAA copolymer, a secondsub-layer comprising polyethylene, and a third sub-layer comprisingpolyethylene.

In some non-limiting examples, the supplemental layer 24 including afirst sub-layer comprising EAA copolymer, a second sub-layer comprisingpolyethylene or polypropylene, and a third sub-layer comprisingpolyethylene or polypropylene is utilized in a headliner substrate, aheadliner cover, a seat cover, etc. In such embodiments, thesupplemental layer(s) 24 including a first sub-layer comprising EAAcopolymer, a second sub-layer comprising polyethylene or polypropylene,and a third sub-layer comprising polyethylene or polypropylene istypically disposed on the first and/or or second surface 14, 16 of thepolyurethane foam core 12 with the EAA copolymer facing the first and/oror second surface 14, 16 of the polyurethane foam core 12.

In other such embodiments, the at least one additional layer 24 (e.g.comprising EAA copolymer) is utilized as a film at a thickness of fromabout 5 to about 50, from about 10 to about 30, from about 12 to about25, or from about 13 to about 25 (e.g. about 15, 16, 17, 18, or 19), μm.In various non-limiting embodiments, all values and ranges of valuesincluding and between those described above are hereby expresslycontemplated for use herein.

In some embodiments, where the additional layer(s) 24 comprises multiplesub-layers, a thicker second sub-layer (e.g. having a thickness of atleast twice the thickness of a first sub-layer, and, if included, athird sub-layer) is utilized. As a non-limiting example, the additionallayer(s) 24 can comprise a first sub-layer layer (e.g. comprising EAAcopolymer) and having a thickness of from about 2 to about 4.5, μm, asecond (or central) sub-layer having a thickness of from about 8 toabout 14, μm, and a third sub-layer having a thickness of from about 2to about 4.5, μm. As another non-limiting example, the additionallayer(s) 24 can comprise a first sub-layer layer (e.g. comprising EAAcopolymer) and having a thickness of from about 2 to about 4 μm, asecond sub-layer having a thickness of from about 8 to about 14, μm.

Further, in some embodiments, the at least one additional layer 24 (e.g.comprising EAA copolymer) is utilized as a film having an Elmdorf tearstrength of from about 15 to about 35 g MD and from about 200 to about540 g TD when tested in accordance with ASTM D1922. In variousnon-limiting embodiments, all values and ranges of values including andbetween those described above are hereby expressly contemplated for useherein.

The composite foam article 10 may optionally include one or more catchlayers. The one or more catch layers “catch” VOCs, i.e., and reduce VOCemissions from the composite foam article 10 and absorb VOCs from withinthe passenger compartment to improve air quality in the passengercompartment. The one or more catch layers can be dispersed in and/ordisposed between any of the aforementioned layers.

The catch layer includes particles of carbon having a surface area ofgreater than about 300 m²/g. Such high surface area carbon is oftenreferred to as activated carbon, active carbon, or activated charcoal.The particles of carbon have small, low-volume pores that increase thesurface area available for adsorption and/or chemical reactions.

Due to its high degree of microporosity, one gram of activated carboncan have a surface area in excess of 3,000 m²/ft. Typically, the surfacearea of the particles of carbon is determined by gas adsorption. Theparticles of carbon absorb VOCs as a function of high surface area.However, in some embodiments, the particles of carbon can be chemicallytreated to further enhance its adsorption properties. In someembodiments, the particles of carbon have a surface area of greater thanabout 300, greater than about 600, greater than about 900, greater thanabout 1,200, greater than about 1,500, greater than about 1,800, greaterthan about 2,100, greater than about 2,400, greater than about 2,700, orgreater than about 3,000, m²/g. Alternatively, in some embodiments, theparticles of carbon have a surface area of from about 500 to about5,000, from about 600 to about 4,500, from about 600 to about 3,500, orfrom about 700 to about 2,500, m²/g. In various non-limitingembodiments, all values and ranges of values including and between thosedescribed above are hereby expressly contemplated for use herein.

If included, the particles of carbon are typically included in thecomposite foam article 10 in the form of particles or powder, as opposedto in sheet form or some other form. In some embodiments, the particlesof carbon have a mean particle size of from about 5 to about 1,000, fromabout 5 to about 100, from about 5 to about 60, from about 5 to about35, from about 8 to about 32, or from about 10 to about 60, μm. The meanparticle size is the mean particle diameter which is calculated as thesize, expressed in μm, for which 50% by weight of granules are smaller.In various non-limiting embodiments, all values and ranges of valuesincluding and between those described above are hereby expresslycontemplated for use herein.

In some embodiments, the particles of carbon are made from a rawmaterial chosen from at least one of coconut shell, coal, and wood. Inone particular embodiment, the particles of carbon are made from coconutshell. Various types of the particles of carbon are commerciallyavailable from: Jacobi Carbons, Inc. of Columbus, Ohio, under thetradename ADDSORB™; from Liberty Carbon Service Inc. of ExcelsiorSprings, Mo.; or from Calgon Carbon Corporation of Pittsburgh, Pa.

In addition to particles of carbon, the catch layer may include variousother absorbents, antioxidants, fillers, and other additives. Forexample, in some embodiments, the catch layer further comprises azeolite. Zeolites are microporous, aluminosilicate minerals. In oneparticular embodiment, the catch layer includes particles of carbon anda zeolite.

In some embodiments, the catch layer comprises carbon in an amount offrom about 2 to about 200, from about 2 to about 50, from about 5 toabout 50, or from about 10 to about 40, g/m². In various non-limitingembodiments, all values and ranges of values including and between thosedescribed above are hereby expressly contemplated for use herein.

It should be appreciated that the composite foam article 10 can includeadditional layers in various configurations. For example, the compositefoam article 10 typically comprises a finished outer layer that facesthe passenger compartment which is disposed adjacent the first skin 18.

In addition to use as a headliner substrate, examples of the compositefoam article 10 described above can be used as seat backs, packagetrays, and load floors with the same or a different combination oflayers.

In many embodiments, the composite foam article 10 has a pre-compressionthickness of from about 2 to about 5 mm, and a post-compressionthickness of greater than about 1.5 mm, greater than about 2 mm, fromabout 1.5 to about 5, or about 2 to about 4.5 mm Pre-compression andpost compression thicknesses a described further below with respect tothe method of forming (e.g. laminating) the composite foam article 10.

In many embodiments, the composite foam article 10 is porous, and itsporosity provides enhanced acoustic properties while its structureprovides enhanced strength. In various embodiments, the composite foamarticle 10 has an air flow resistance of greater than about 250, greaterthan about 500, greater than about 750, from about 500 to about 7,500,or from about 500 to about 5,000, mks rayls (Pas/m) when tested inaccordance with ASTM C522-03. ASTM C522-03 covers the measurement ofairflow resistance and the related measurements of specific airflowresistance and airflow resistivity of porous materials that can be usedfor the absorption and attenuation of sound. ASTM C522-03 is designedfor the measurement of values of specific airflow resistance rangingfrom 100 to 10,000 inks rayls (Pas/m).

In many embodiments, the composite foam article 10 has a weight per unitarea of from about 500 to about 1,200, from about 750 to about 1,200,from about 750 to about 1,000, from about 800 to about 1,200, from about800 to about 1,000, or about 700 to about 1,000, g/m². The first andsecond skin 18, 20 cumulatively contribute from about 25 to about 60, orfrom about 30 to about 55, % of the total weight per unit area of thecomposite foam article 10. In various non-limiting embodiments, allvalues and ranges of values including and between those described aboveare hereby expressly contemplated for use herein.

In many embodiments, the composite foam article 10 has apost-compression stiffness of greater than about 8, greater than about9, greater than about 10, greater than about 12, greater than about 14,from about 10 to about 25, from about 12 to about 25, or from about 14to about 25, N/mm at a post compression thickness of about 4, mm whentested in accordance with SAE J949 at room temperature (about 23° C.)and/or at elevated temperature (about 80° C.). In various non-limitingembodiments, all values and ranges of values including and between thosedescribed above are hereby expressly contemplated for use herein.

In some embodiments, the composite foam article 10 has apost-compression stiffness of greater than about 3 N/mm, greater thanabout 3.5 N/mm, or from about 3 N/mm to about 12 N/mm, and a postcompression thickness of about 2 mm when tested in accordance with SAEJ949 at room temperature (about 23° C.) and/or at elevated temperature(about 80° C.). In various non-limiting embodiments, all values andranges of values including and between those described above are herebyexpressly contemplated for use herein.

In many embodiments, the composite foam article 10 has a strength ofgreater than about 10, greater than about 11, greater than about 12,greater than about 13, greater than about 14, greater than about 15,greater than about 16, greater than about 17, greater than about 18,greater than about 19, greater than about 20, greater than about 21,greater than about 22, greater than about 25, greater than about 30,greater than about 35, greater than about 40, greater than about 45, orgreater than about 50, N at a post-compression thickness of greater thanabout 2, from about 2 to about 5, from about 2 to about 4, about 2 mm,or about 4 mm, when tested in accordance with SAE J949 at roomtemperature (about 23° C.) and/or at elevated temperature (about 80°C.). In various non-limiting embodiments, all values and ranges ofvalues including and between those described above are hereby expresslycontemplated for use herein.

A method of forming (e.g. laminating) some embodiments of the compositefoam article 10 is also disclosed. Notwithstanding the “dry” method orprocess disclosed below, it should be appreciated that the compositefoam article 10 of the subject disclosure formed with “wet” and otherprocesses, which are also known in the art, are contemplated herein aswell.

In one embodiment, the method includes the steps of:

-   -   positioning a blank in a heating device, the blank comprising:        -   the polyurethane foam core 12 (as is described above)            presenting a first surface 14 and a second surface 16 facing            opposite the first surface 14, the polyurethane foam core 12            having: pre-compression thickness of from about 2 to about            5, or from about 3 to about 5 mm; and a density of from            about 45 to about 80 kg/m³;        -   the first skin 18 (as is described above) disposed on the            first surface 14; and        -   a second skin 20 (as is described above) disposed on the            second surface 16;    -   heating the laminated blank at a temperature above the melting        point of the polymeric binder to cause the polymer to melt and        the layers of the composite foam article 10 to adhere to one        another; and    -   compressing the laminated blank to form the composite foam        article 10 having a strength of greater than 17 N at a        post-compression thickness of greater than about 2 mm when        tested in accordance with SAE J949 at ambient temperature (about        23° C.).

In a typical embodiment, the step of positioning a blank in a heatingdevice is further described as laminating a blank at a temperature offrom about 150 to about 250, or from about 170 to about 230, ° C. In atypical embodiment, the step of laminating can be described as includingthe sub-step of surface heating the blank (conductive heating). In someembodiments, the step of positioning a blank in a heating device can bedescribed as laminating a headliner substrate.

In a typical embodiment, the method also includes the step of moldingthe laminated blank into a pre-determined shape (thermoforming).Typically, the step of heating the laminated blank and molding thelaminated blank are conducted sequentially.

In a typical embodiment, the laminated blank is then subjected to atemperature of at least about 150° C. in an oven and then transferred toa forming tool at ambient temperatures (about 23° C.) for a period oftime sufficient to cause the layers to form a shape, e.g. a contouredheadliner shell shape, as defined in the forming tool. In this moldingor thermoforming step, the finished outer layer (e.g. facing materialssuch as knitted fabrics pre-bonded to a thin layer of flexible foam ornon-woven scrims) can be introduced. In the example of headliners, thefinished outer layer (headliner coverstock) becomes the “A” surface ofthe contoured headliner shell with the laminated blank serving as acontoured structural core (e.g. headliner substrate). In someembodiments, the steps of heating the laminated blank, compressing thelaminated blank, and molding the laminated blank can be described asmolding a headliner.

In many embodiments, the heating step in the thermoforming operation isconducted at a temperature of at least about 120, from about 120 toabout 250, or from about 150 to about 220, ° C. In various non-limitingembodiments, all values and ranges of values including and between thosedescribed above are hereby expressly contemplated for use herein.

Many of the method steps described herein are included in U.S. PatentApplication Publication No. 2008/0311336, which is incorporated hereinin its entirety.

Referring now to FIG. 2, an exploded cross-sectional view of oneembodiment of the composite foam article 10 which can be utilized as aheadliner substrate is illustrated. The polyurethane foam core 12comprises a semi-rigid polyurethane foam and presents the first surface14 and the second surface 16 facing opposite the first surface 14. Thefirst skin 18 is disposed on the first surface 14 and the second skin 20is disposed on the second surface 16. The first and second skins 18, 20comprise a plurality of glass fibers and a polymeric (e.g.polypropylene) binder. Those of skill in the art understand that thelayers of the embodiments of the composite foam article 10 in FIG. 1 anddescribed elsewhere herein intermingle as a result of the laminationprocess such that there may be a gradual interface between the layers asa result of the melting of the polymeric materials in the composite foamarticle 10 and the subsequent lamination and molding of the layers.Further, the embodiment of FIG. 2 includes three additional polymericlayers 24, 24′, and 24″. In some embodiments, additional polymericlayers 24, 24′ can comprise high density polyethylene while 24″ cancomprise poly(ethylene terephthalate) scrim. Of course, FIG. 2 does notinclude a headliner coverstock fabric/flexible foam or non-woven facingmaterial, which would typically be applied to this composite foamarticle 10 in the thermoforming step to produce an automotive headliner.

Referring now to FIG. 11, an exploded cross-sectional view of anotherembodiment of the composite foam article 110 which can be utilized as aheadliner substrate is illustrated. The polyurethane foam core 112comprises a semi-rigid polyurethane foam and presents the first surface114 and the second surface 116 facing opposite the first surface 114.The first skin 118 is disposed on the first surface 114 and the secondskin 120 is disposed on the second surface 116. The first and secondskins 118, 120 comprise a plurality of glass fibers and a polypropylenepolymeric binder. Those of skill in the art understand that the layersof the embodiments of the composite foam articles 110 in FIG. 11 anddescribed elsewhere herein intermingle as a result of the laminationprocess such that there may be a gradual interface between the layers asa result of the melting of the polymeric materials in the composite foamarticle 110 and the subsequent lamination and molding of the layers.

Further, the embodiment of FIG. 11 includes three additional polymericlayers 124, 124′, and 124″. In contrast to the example of FIG. 2, whichincludes additional layers 24, 24′ comprising high density polyethylene,FIG. 11 includes additional layers 124, 124′ comprising EAA copolymer.In some embodiments, like in FIG. 2, additional layer 124″ of FIG. 11can comprise poly(ethylene terephthalate) scrim. Of course, FIG. 11 doesnot include a headliner coverstock fabric/flexible foam or non-wovenfacing material, which would typically be applied to this composite foamarticle 110 in the thermoforming step to produce an automotiveheadliner.

However, referring now to FIG. 12, the composite foam article 210 can beused as a headliner coverstock. In some such embodiments, the headlinercoverstock comprises EAA copolymer. The composite foam article 210includes polyurethane foam core 212 presenting the first surface 214 andthe second surface 216 facing opposite the first surface 214. Further,at least one additional layer 224 comprising an EAA copolymer isdisposed on said first surface 214, and a non-woven, woven, leather, orvinyl layer 226 is disposed on said second surface 216. Optionally, asecond additional polymeric layer, e.g. comprising EAA copolymer, can beincluded between the polyurethane foam core 212 and a non-woven, woven,leather, or vinyl cover layer 226 which is disposed on said secondsurface 216.

Referring now to FIG. 12, FIG. 12 provides an expanded cross-sectionalview of one embodiment of the composite foam article 210 which can beutilized as a headliner coverstock. In the embodiment of FIG. 12, thecomposite foam article 210 (e.g. headliner coverstock) includes thepolyurethane foam core 212 comprising a flexible and/or a viscoelasticpolyurethane foam and presents the first surface 214 and the secondsurface 216 facing opposite the first surface 214. An additional layer224 comprising an EAA copolymer is disposed on the first surface 214,and the cover layer 226 (non-woven, woven, leather, or vinyl) isdisposed on the second surface 216.

Referring now to FIG. 13, an exploded cross-sectional view of anotherembodiment of the composite foam article 310 which can be utilized as aheadliner substrate is illustrated. the composite foam article 310 ofFIG. 13, includes a polyurethane foam core 312, first and second skins318, 318′ comprising fiberglass and polypropylene thereon, as well astwo additional layers 324A, 324A′ comprising first and second additionallayers comprising EAA copolymer film disposed between the first andsecond skins 318, 318′ and the surfaces 314, 316 of the polyurethanefoam core 312. Two more additional layers 324B, 324B′ comprisingpolypropylene are included along with a backing scrim (e.g. comprisingPET) 350. It is to be appreciated that the polyurethane foam core 312,first and second skins 318, 318′ and additional layers 324A, 324A′,324B, and 324B′ can comprise the various materials described above withreference to the polyurethane foam core 312, skins 318, 318′, andadditional layers 324A, 324A′, 324B, 324B′ described above and all suchembodiments are contemplated.

In some embodiments, the composite foam article 10 described herein andincluding an additional polymeric layer comprising EAA COPOLYMER is usedin/is a seat component, e.g. seat trim. Referring again to FIG. 12, thecomposite foam article 210 illustrated can also be used as a seatingcomponent. To this end, the composite foam article 210 may be a seatingcomponent and referred to as such. As used throughout this disclosure,the term “seat component” is used in connection with one, some or all ofa cushion (i.e., the portion of the seat on which the occupant/passengersits), a back or back rest (i.e., the portion of the seat which supportsthe back of the occupant/passenger), and a side bolster (i.e., theextension of the cushion, back or the back rest, which laterallysupports the occupant/passenger).

For example, in some embodiments, the composite foam article 210 is aseat component comprising:

-   -   the polyurethane foam core 212 presenting the first surface 214        and the second surface 216 facing opposite the first surface        214;    -   an additional polymeric layer 224 comprising an EAA copolymer is        disposed on the first surface 214,    -   an additional polymeric layer comprising an EAA copolymer (not        shown) may be optionally disposed on the first surface 214; and    -   the cover layer 226 (non-woven, woven, leather, or vinyl) is        disposed on the second surface 216.

In many seating embodiments, the composite foam article 10 comprises aflexible and/or a viscoelastic polyurethane foam.

Further, in such seating embodiments, the non-woven, woven, leather, orvinyl layer 24 may be flame bonded to the second surface 16. In suchembodiments, the composite foam article 10 has a total thickness of fromabout 1 to about 10, mm post flame bonding.

It is to be appreciated that the composite foam articles 10 describedabove can be used in any combination. Various composite foam articles 10contemplated herein include laminates for use as headliners, loadfloors, seat components, sun shades, sun visors, rear seat back panels,and package trays comprising various combinations of the layersdescribed.

The following examples are intended to illustrate the present disclosureand are not to be read in any way as limiting to the scope of thepresent disclosure.

EXAMPLES

Examples of the composite foam article are described in an automotiveheadliner application below. Generally, the Examples show how variousembodiments of the composite foam article of this disclosure providesexcellent strength and stiffness at different compressions andthicknesses.

Examples 1 and 2

The composite foam article of the headliner substrate of Example 1 isdescribed in FIG. 2 and Table 1 below. The composite foam article of theheadliner substrate of Comparative Example 1 is also described Table 1below. Both example composite foam articles include a polyurethane foamcore with first and second skins comprising fiberglass and polypropylenethereon. In Table 1, Example 1 and Comparative Example 1 are lightlycompressed (at 4 mm), and more significantly compressed (from 4 mm to 2mm), which often occurs in many areas of a formed headliner.

TABLE 1 Total Weight/Unit Polyurethane Total Thickness Area Foam Core(mm) (g/m²) Comparative Semi-rigid PU 4 914 g/m² Example 1 Foam Initialdensity: 40 kg/m³ Example 1 Semi-rigid PU 4 875 g/m² Foam Initialdensity: 69 kg/m³ Comparative Semi-rigid PU 2 914 g/m² Example 1 Foamcompressed Initial density: 40 kg/m³ Example 1 Semi-rigid PU 2 875 g/m²compressed Foam Initial density: 69 kg/m³

Example 1 and Comparative Example 1 are tested at a thickness of about 2mm and about 4 mm for strength and stiffness in accordance with SAEJ949, and the results are set forth in FIGS. 3-6 at room temperature(about 23° C.) and at elevated temperature (about 80° C.).

Referring now to FIGS. 3-6, Example 1 which includes a polyurethane foamcore having a density of 69 kg/m³ and includes the first and secondskins for a total weight per unit area of 875 g/m² exhibitssignificantly higher strength and stiffness than Comparative Example 1which has a polyurethane foam core with density of 40 kg/m³ and includesthe first and second skins for a total weight per unit area of 914 g/m².As such, Example 1, has a polyurethane foam core with an initial densityof 69 kg/m³, and has a weight per unit area of 875 g/m² exhibitssuperior strength and stiffness relative to Comparative Example 1 atboth 4 mm and 2 mm and also at room temperature (about 23° C.) and atelevated temperature (about 80° C.).

Further, Example 1 exhibits a firm feel to the touch (is less spongy)while Comparative Examples 1 exhibits a softer feel to the touch, e.g.when applying thumb pressure.

Example 1 has a flexible polyurethane foam core, which has a density of69 kg/m³, 80 psi CFD (at 10% defection) at 23° C., and 30% elongation atforming temperature (200° C.). Surprisingly, the polyurethane foam coreof Example 1 imparts the excellent strength and flexibilitycharacteristics set forth in FIGS. 3-6. Differences between the foamcore of Example 1 and Comparative Example 1 are set forth in Table 2below.

TABLE 2 Comparative Example 1 Example 1 Top skin (g/m²) 372 298 Foam -(g/m²; 3.75 mm thick) 150 259 Bottom skin (g/m²) 392 318 Total ArticleWeight (g/m²) 914 875 Weight % Foam     16%     30% (based on 100 PBWArticle) Foam Core (polyurethane) Density (kg/m³)  40  69 Foam CoreCFD - 20% 23° C.  30  80 (PSI) Foam Core CFD - 20% 165° C.  27  90 (N)

Table 3 below provides a description of the Examples 1 and 2 andComparative Examples 1-4.

TABLE 3 Example/ Comparative Example Description Structure Thickness(mm) Example 1 Described Above Sandwich 4 Example 1 Described AboveSandwich 2 Compressed Example 2 Like Example 1, Sandwich 4 except weightper unit area of 675 g/m². Example 2 Similar to Example 1 Sandwich 2Compressed compressed, except weight per unit area of 675 g/m².Comparative Described Above Sandwich 4 Example 1 Comparative DescribedAbove Sandwich 2 Example 1 Compressed Comparative Traditional, lowerSandwich 4 Example 2 density PU foam, Less Skin Than Comparative Example1 Comparative PP/glass Composite Non-Sandwich 4 Example 3 Headliner,weight per Composite unit area of 880 g/m² Comparative PP/glassComposite Non-Sandwich 4 Example 4 Headliner, weight per Composite unitarea of 1280 g/m² Comparative Traditional, lower Sandwich 2 Example 2density PU foam, Compressed Less Skin Than Comparative Example 1compressed Comparative PP/glass Composite Non-Sandwich 2 Example 3Headliner, weight per Composite Compressed unit area of 880 g/m²Comparative PP/glass Composite Non-Sandwich 2 Example 4 Headliner,weight per Composite Compressed unit area of 1280 g/m²

Referring now to FIGS. 7-10, the strength and stiffness of Examples 1and 2 are compared to various comparative substrates to illustrate theirsurprisingly strong performance characteristics.

In view of FIGS. 7-10, the high density, high modulus polyurethane foamcore of the (69 kg/m³, 80 psi CFD (at 10% defection) and 23° C., and 30%elongation at forming temperature of 200° C.) and the skins of theExamples described (foam weight % increased to 30 weight % of 100 PBWsubstrate), dramatic improvements in strength and stiffness performanceat lower weight per unit areas are demonstrated.

Examples 3-6

The composite foam article of the headliner substrates of Examples 3-6and Comparative Examples 5-8 are described in Table 4 below. Examples3-6 include a polyurethane foam core with first and second skinscomprising fiberglass and polypropylene thereon as well as twoadditional layers comprising EAA copolymer film (13 gsm) disposedbetween the first and second skins and the surfaces of the polyurethanefoam core. Two more additional layers comprising polypropylene areincluded along with a backing scrim. In contrast to Examples 3-6,Comparative Examples 5-8 utilize two additional layers comprising HDPEfilm (28 gsm) disposed between the first and second skins and thesurfaces of a polyurethane foam core, but from the EAA copolymer layersbeing replaced, the configuration of layers of Comparative Examples 5-8is the same as that of Examples 3-6. Please refer further to FIG. 13 foran exploded view of the headliner substrate configuration of Examples3-6 and comparative Examples 5-8.

TABLE 4 Total Thickness Air Permeability (mm) (ft³/ft²/min) Example 3 425 Example 4 6 16 Example 5 8 17 Example 6 10 17 Comp. Ex. 5 4 2 Comp.Ex. 6 6 8 Comp. Ex. 7 8 8 Comp. Ex. 8 10 5

Referring now to Table 4, Examples 3-6, which include a polyurethanefoam core with first and second skins comprising fiberglass andpolypropylene thereon as well as two additional layers comprising EAAcopolymer film (13 gsm), exhibit excellent airflow relative toComparative Examples 5-8 which utilize two additional layers comprisingHDPE film (28 gsm).

Referring now to FIG. 14, the improved air flow contributes to improvedsound absorption at higher frequencies. FIG. 14 is a graphical analysisof the sound absorption of Example 5 and Comparative Example 7. Example5 exhibits improved sound absorption at higher frequencies, which isdesirable in automotive applications.

Referring now to FIGS. 15 and 16, the two additional layers comprisingEAA copolymer film (13 gsm) surprisingly provide a robust bond betweenthe polyurethane foam core and the first and second skins of theExamples. In fact, the two additional layers of the Examples comprisingEAA copolymer are utilized at 13 grams per square meter whereas the twoadditional layers of the Comparative Examples comprising HDPE are usedat 28 grams per square meter and the EAA copolymer still outperforms theHDPE. In other words, the Examples including the EAA copolymer generallyoutperform the Comparative Examples, which include over two times theHDPE. FIG. 15 is a graphical analysis comparing the peel strengthbetween the first skin (on the “A side” of the substrate) and thepolyurethane foam core of Examples 3, 4, and 5 and Comparative Examples5, 6, and 7. FIG. 16 is a graphical analysis comparing the peel strengthbetween the second skin (on the “C side” of the substrate) and thepolyurethane foam core of Examples 3, 4, and 5 and Comparative Examples5, 6, and 7. The “non-toasted” designation pertains to the substrateboard condition after lamination. The “toasted” designation pertains toheating this board to approximately 200° C. and then compressing itlightly in a flat plaque tool to simulate the thermoforming operation.

Examples 3-6 and Comparative Examples 5-8 are tested via a three pointbending test which provides strength (Fmax), stiffness, and modulus ofelasticity in bending (Emod) data. Referring now to FIG. 18, Examples3-6 exhibit equal if not better strength than respective ComparativeExamples 5-8. Referring now to FIG. 18, Examples 3-6 exhibit equal ifnot better stiffness than respective Comparative Examples 5-8.

Sag testing is utilized to determine strength under high temperature. Totest sag, 2″×10″ samples of each respective Example/Comparative Exampleis held stationary at one end of the sample and a 22 g weight is placedon the other end of the sample. The samples are placed in an oven at 80°C. and their initial height is measured. Every hour for five hours thetemperature increases by 10° C. and the drop in height, or “sag”, isrecorded. Referring now to FIG. 19, Examples 3 and 4 exhibit equal ifnot better sag than respective Comparative Examples 5 and 6.

In summary, Examples 3-6 exhibit significantly improved air flow andpeel strength over the respective Comparative Examples. Notably, thepeel strength significantly improved for the non-toasted board (i.e.lamination condition). This provides for a wider process window inlamination to meet specified non-toasted board peel strengthrequirements.

From an air flow perspective, the additional layer comprising EAAcopolymer provides excellent acoustic performance and peel in partbecause it melts to form a porous layer which has excellent adhesion topolyurethane. The additional layer comprising EAA copolymer (e.g. havingthicknesses from about 5 to about 30, from 10 to about 20, or about 13gsm (g/m²)) has pores or openings similar to that of the polyurethanefoam core layer. In FIG. 20, an enlarged image of the additional layerin Example 4 comprising EAA copolymer is shown covering portions of asurface of the foam core layer, while not covering various portions ofthe surface and pores of the foam core layer. The area of the surfacethat is covered by the additional layer comprising EAA is shown instippling. FIG. 20 illustrates how the composite foam articles of thisdisclosure are able to maintain high air flow after the addition of theadditional layer comprising EAA copolymer because the porosity of thepolyurethane foam core in not impacted by the EAA copolymer.Advantageously, adhesion of the layers to the polyurethane foam coreincreases with use of the additional layer comprising EAA too.

Examples 3-6 also exhibit equivalent strength, stiffness, and sagrelative to the respective Comparative Examples. Further, Examples 3-6produce improved performance over comparative examples while having areduced weight per square meter.

It is to be understood that the appended claims are not limited toexpress any particular compounds, compositions, or methods described inthe detailed description, which may vary between particular embodimentswhich fall within the scope of the appended claims. With respect to anyMarkush groups relied upon herein for describing particular features oraspects of various embodiments, it is to be appreciated that different,special, and/or unexpected results may be obtained from each member ofthe respective Markush group independent from all other Markush members.Each member of a Markush group may be relied upon individually and or incombination and provides adequate support for specific embodimentswithin the scope of the appended claims.

It is also to be understood that any ranges and subranges relied upon indescribing various embodiments of the instant disclosure independentlyand collectively fall within the scope of the appended claims, and areunderstood to describe and contemplate all ranges including whole and/orfractional values therein, even if such values are not expressly writtenherein. One of skill in the art readily recognizes that the enumeratedranges and subranges sufficiently describe and enable variousembodiments of the instant disclosure, and such ranges and subranges maybe further delineated into relevant halves, thirds, quarters, fifths,and so on. As just one example, a range “of from 0.1 to 0.9” may befurther delineated into a lower third, i.e., from 0.1 to 0.3, a middlethird, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9,which individually and collectively are within the scope of the appendedclaims, and may be relied upon individually and/or collectively andprovide adequate support for specific embodiments within the scope ofthe appended claims. In addition, with respect to the language whichdefines or modifies a range, such as “at least,” “greater than,” “lessthan,” “no more than,” and the like, it is to be understood that suchlanguage includes subranges and/or an upper or lower limit. As anotherexample, a range of “at least 10” inherently includes a subrange of fromat least 10 to 35, a subrange of from at least 10 to 25, a subrange offrom 25 to 35, and so on, and each subrange may be relied uponindividually and/or collectively and provides adequate support forspecific embodiments within the scope of the appended claims. Finally,an individual number within a disclosed range may be relied upon andprovides adequate support for specific embodiments within the scope ofthe appended claims. For example, a range “of from 1 to 9” includesvarious individual integers, such as 3, as well as individual numbersincluding a decimal point (or fraction), such as 4.1, which may berelied upon and provide adequate support for specific embodiments withinthe scope of the appended claims.

The instant disclosure has been described in an illustrative manner, andit is to be understood that the terminology which has been used isintended to be in the nature of words of description rather than oflimitation. Obviously, many modifications and variations of the instantdisclosure are possible in light of the above teachings. It is,therefore, to be understood that within the scope of the appendedclaims, the instant disclosure may be practiced otherwise than asspecifically described.

1. A composite foam article comprising: a polyurethane foam corepresenting a first surface and a second surface facing opposite saidfirst surface, a first skin disposed on said first surface comprising aplurality of fibers and a polymeric binder; a second skin disposed onsaid second surface comprising a plurality of fibers and a polymericbinder; and at least one additional layer comprising an ethylene acrylicacid (“EAA”) copolymer dispersed in and/or disposed between any of saidaforementioned skins and core.
 2. The composite foam article set forthin claim 1, wherein said polymeric binder comprises a polymer selectedfrom polyethylene and polypropylene.
 3. The composite foam article setforth in claim 1, wherein said fibers comprise a material selected frompolymeric, ceramic, glass, metal, mineral, and carbon.
 4. The compositefoam article set forth in claim 1, wherein said at least one additionallayer is formed from an EAA copolymer film.
 5. The composite foamarticle set forth in claim 4, wherein said at least one additional layeris formed from a multi-layered film.
 6. The composite foam article setforth in claim 1, wherein said at least one additional layer comprisespolyethylene and EAA copolymer.
 7. The composite foam article set forthin claim 1, wherein said at least one additional layer comprises a firstsub-layer comprising EAA copolymer, a second sub-layer comprisingpolyethylene or polypropylene, and a third sub-layer comprisingpolyethylene or polypropylene, wherein said second sub-layer is disposedbetween said first and said third-sub layers.
 8. The composite foamarticle set forth in claim 1 comprising two additional layers comprisingEAA copolymer, a first additional layer comprising EAA copolymerdisposed between said polyurethane foam core and said first skin and asecond additional layer comprising EAA copolymer disposed between saidpolyurethane foam core and said second skin.
 9. The composite foamarticle set forth in claim 8 comprising two more additional layerscomprising polypropylene, a third additional layer comprisingpolypropylene disposed on said first skin, and a fourth additional layercomprising polypropylene disposed on said second skin.
 10. The compositefoam article set forth in claim 9 wherein said first and said secondskins comprise glass fiber and polypropylene powder and/or saidpolyurethane foam core is a polyurethane foam core comprising semi-rigidpolyurethane foam having a density of from about 22 to about 80, kg/m³.11. The composite foam article set forth in claim 1, wherein said atleast one additional layer is utilized in an amount from about 8 toabout 30, g/m².
 12. A vehicular headliner substrate, headlinercoverstock, a sunshade, a sun visor, a package tray, a seat back, or aload floor comprising said composite foam article set forth in claim 1.13. A method of making a composite foam article, said method comprisingthe steps of: positioning a blank in a heating device, the blankcomprising: a polyurethane foam core presenting a first surface and asecond surface facing opposite the first surface; a first additionallayer comprising an ethylene acrylic acid copolymer disposed on thefirst surface; a first skin disposed on the first additional layer andcomprising a plurality of fibers and a polymeric binder; and a secondadditional layer comprising an ethylene acrylic acid copolymer disposedon the second surface; a second skin disposed on the second additionallayer and comprising a plurality of fibers and a polymeric binder;heating the blank at a temperature above the melting point of thepolymeric binder to cause the polymer to melt and the layers of thecomposite foam article to adhere to one another; and compressing theblank to form the composite foam article.
 14. The method set forth inclaim 13, wherein the step of compressing is further defined as moldingthe blank into a pre-determined shape.
 15. The method set forth in claim13, wherein the step of positioning a blank in a heating device isfurther described as laminating a blank at a temperature of from about150 to about 250, ° C.
 16. The method set forth in claim 13, wherein thecomposite foam article has a post compression weight per unit area offrom about 500 to about 1,000 g/m².
 17. A composite foam articlecomprising: a polyurethane foam core presenting a first surface and asecond surface facing opposite said first surface; at least oneadditional layer comprising an ethylene and acrylic acid copolymerdisposed on said first surface; and a non-woven, woven, leather, orvinyl layer disposed on said second surface.
 18. The composite foamarticle set forth in claim 17, wherein said polyurethane foam corecomprises a flexible and/or a viscoelastic polyurethane foam.
 19. Thecomposite foam article set forth in claim 17, wherein said at least oneadditional layer comprises a first sub-layer comprising EAA copolymer, asecond sub-layer comprising polyethylene or polypropylene, and a thirdsub-layer comprising polyethylene or polypropylene, wherein said secondsub-layer is disposed between said first and said third-sub layers. 20.The composite foam article set forth in claim 17, wherein said at leastone additional layer is utilized in an amount from about 8 to about 30g/m².
 21. The composite foam article set forth in claim 17, wherein saidat least one additional layer is utilized as a film having a tensileelongation of from about 200 to about 400% MD and from about 350 toabout 550% TD when tested in accordance with ASTM D882.
 22. Thecomposite foam article set forth in claim 17, wherein said non-woven,woven, leather, or vinyl layer is flame bonded to said second surface,and has a total thickness of from about 1 to about 10, mm post flamebonding.
 23. An automotive seat comprising the composite foam articleset forth in claim 22.